Methods and apparatus for maintaining effective operation of apparatus for candling avian eggs

ABSTRACT

Egg candling methods and apparatus are provided wherein the optical path between a light source and light detector is monitored for obscuring debris and/or malfunctions. A method of candling eggs includes illuminating an egg with light from a light source; receiving light passing through the egg at a light detector; generating an output signal that corresponds to light received at the light detector for the egg; and analyzing the output signal to determine whether the optical path between the light source and light detector has been altered. In response to determining that a respective optical path has been altered, the light source and/or light detector is cleaned and/or inspected for malfunctions. Cleaning the light source and/or light detector may include wiping a surface of the light source and/or light detector and/or spraying a surface of the light source and/or light detector with a fluid.

RELATED APPLICATION

The present application claims priority from and is a continuation ofU.S. Non-Provisional application Ser. No. 11/487,614, filed on Jul. 17,2006, now U.S. Pat. No. 7,573,566, granted Aug. 11, 2009, which claimsthe benefit of and priority to U.S. Provisional Application No.60/703,044, filed on Jul. 27, 2005, all of which are incorporated byreference herein for all purposes.

FIELD OF THE INVENTION

The present invention relates generally to eggs and, more particularly,to methods and apparatus for processing eggs.

BACKGROUND OF THE INVENTION

Discrimination between poultry eggs on the basis of some observablequality is a well-known and long-used practice in the poultry industry.“Candling” is a common name for one such technique, a term which has itsroots in the original practice of inspecting an egg using the light froma candle. As is known to those familiar with eggs, although egg shellsappear opaque under most lighting conditions, they are in realitysomewhat translucent, and when placed in front of direct light, thecontents of the egg can be observed.

Eggs which are to be hatched to live poultry are typically candledduring embryonic development to identify clear, rotted, and dead eggs(collectively referred to as “non-live eggs”). Non-live eggs aretypically removed from incubation to increase available incubator space.In many instances it is desirable to introduce a substance, via in ovoinjection, into a live egg prior to hatch. Injections of varioussubstances into avian eggs are typically employed in the commercialpoultry industry to decrease post-hatch mortality rates or increasegrowth rates of hatched birds. Examples of substances that have beenused for, or proposed for, in ovo injection include vaccines,antibiotics and vitamins. In ovo treatment substances and methods of inovo injection are described, for example, in U.S. Pat. No. 4,458,630 toSharma et al. and U.S. Pat. No. 5,028,421 to Fredericksen et al.

In ovo injections of substances typically occur by piercing an egg shellto create a hole therethrough (e.g., using a punch or drill), extendingan injection needle through the hole and into the interior of the egg(and in some cases into the avian embryo contained therein), andinjecting one or more treatment substances through the needle. Anexample of an in ovo injection device is disclosed in U.S. Pat. No.4,681,063 to Hebrank. This device positions an egg and an injectionneedle in a fixed relationship to each other, and is designed forhigh-speed automated injection of a plurality of as eggs. The selectionof both the site and time of injection treatment can impact theeffectiveness of the injected substance, as well as the mortality rateof the injected eggs or treated embryos. See, for example, U.S. Pat. No.4,458,630 to Sharma et al., U.S. Pat. No. 4,681,063 to Hebrank, and U.S.Pat. No. 5,158,038 to Sheeks et al.

In commercial poultry production, typically only about 60% to 90% ofcommercial broiler eggs hatch. Eggs that do not hatch include eggs thatwere not fertilized, as well as fertilized eggs that have died.Infertile eggs may comprise from about 5% up to about 25% of all eggs ina set. Due to the number of non-live eggs encountered in commercialpoultry production, the increasing use of automated methods for in ovoinjection, and the cost of treatment substances, an automated method foraccurately identifying live eggs and selectively injecting only liveeggs, is desirable.

There are other applications where it is important to be able toidentify live and non-live eggs. One of these applications is thecultivation and harvesting of vaccines in live eggs (referred to as“vaccine production eggs”).

For example, human flu vaccine production is accomplished by injectingseed virus into a chicken egg at about day eleven of embryonicdevelopment (Day-11 egg), allowing the virus to grow for about two days,euthanizing the embryo by cooling the egg, and then harvesting theamniotic fluid from the egg. Typically, eggs are candled beforeinjection of a seed virus to facilitate removal of non-live eggs.Vaccine production eggs may be candled one or more days prior toinjection of a seed virus therein. Identification of live eggs invaccine production is important because it is desirable to prevent seedvaccine from being wasted in non-live eggs and to reduce costsassociated with transporting and disposing of non-live eggs.

U.S. Pat. Nos. 4,955,728 and 4,914,672, both to Hebrank, describe acandling apparatus that uses infrared detectors and the infraredradiation emitted from an egg to distinguish live from infertile eggs.U.S. Pat. No. 5,745,228 to Hebrank et al. describes a candling apparatusthat includes a photodetector and a photoemitter that are configured tobe positioned on opposite sides of an egg. Light is generated in shortbursts from each photoemitter and the corresponding photodetectormonitors while it's corresponding photoemitter is operational. A flat ofeggs is continuously “scanned” as it moves through the candlingapparatus with each detector-source pair active while at least adjacent,and preferably all other, pairs are quiescent.

Unfortunately, commercial egg candling devices that utilize light (oregg opacity) to evaluate the condition of an egg usually operate in adirty environment that can reduce the accuracy of such devices as theoptical path is altered by debris and/or other materials that accumulateon the optical surfaces. Operators of machines using these candlingdevices may not have the training or motivation to keep these devicesclean, and/or may not be able to easily access these devices to cleanthem. For example, a candling apparatus having a light source abovemoving flats of eggs and light detectors below the moving flats of eggscan have the detectors obscured by a fine layer of egg shell, chunks ofegg shell, egg albumin, yoke or rotten innards, wash water, etc. Smallaccumulations of debris/material typically have a limited effect on theaccuracy of an egg candling device. However, opaque materials likechunks of shell or rotten egg materials can reduce received light sothat clear eggs may be interpreted by a candling apparatus as live eggs.Furthermore, accumulations of transparent materials, like albumin orwater can act as a lens that conducts light reflected off adjacent eggsinto the detector so that live eggs can be misinterpreted as being cleareggs. Exploding eggs, that are not uncommon, can spray both lightdetectors and light sources.

SUMMARY OF THE INVENTION

In view of the above discussion, egg candling methods and apparatus areprovided wherein the optical path between a light source and lightdetector is monitored for obscuring debris and/or equipmentmalfunctions. According to some embodiments of the present invention, amethod of candling eggs includes illuminating an egg with light from alight source; receiving light passing through the egg at a lightdetector; generating an output signal that corresponds to light receivedat the light detector for the egg; and analyzing the output signal todetermine whether the optical path between the light source and lightdetector has been altered (i.e., the optical bath has been blocked orpartially blocked by debris/material, the light source and/or lightdetector malfunctioned, etc.). In response to determining that arespective optical path has been altered, the light source and/or lightdetector is cleaned and/or inspected for malfunctions. According to someembodiments of the present invention, cleaning the light source and/orlight detector may include wiping a surface of the light source and/orlight detector and/or spraying a surface of the light source and/orlight detector with a fluid (e.g., a cleaning fluid, water, air, etc.).

According to some embodiments of the present invention, a candlingapparatus includes a plurality of pairs of light sources and lightdetectors in spaced apart relationship such that a carrier of eggs maypass therebetween. Each light source/light detector pair is operativelyassociated with a processor, and each light source/light detector pairdefines a respective optical channel. In some embodiments of the presentinvention the light sources will be below the eggs and the lightdetectors above, and in other embodiments the light detectors will bebelow the eggs and the light sources above the eggs.

A method of candling eggs via the candling apparatus includesilluminating eggs in a carrier with light from the light sources,wherein the eggs are arranged in rows and columns within the carrier,and wherein each egg in a row is positioned between a respective lightsource/light detector pair; receiving light passing through each egg ata corresponding light detector; generating an output signal thatcorresponds to light received at a light detector for each respectiveegg; and analyzing the output signals of each optical channel todetermine whether the optical path between any of the light source/lightdetector pairs has been altered. In response to determining that arespective optical path has been altered, the light source and/or lightdetector is cleaned and/or inspected for malfunctions. According to someembodiments of the present invention, cleaning the light source and/orlight detector may include wiping a surface of the light source and/orlight detector and/or spraying a surface of the light source and/orlight detector with a fluid (e.g., a cleaning fluid, water, air, etc.).

According to some embodiments of the present invention, analyzing theoutput signals of each optical channel to determine whether the opticalpath between any of the light source/light detector pairs has beenaltered includes detecting whether an average opacity value of cleareggs candled via an optical channel has dropped below an average opacityvalue of clear eggs candled via the other optical channels.

According to some embodiments of the present invention, analyzing theoutput signals of each optical channel to determine whether the opticalpath between any of the light source/light detector pairs has beenaltered includes detecting a drop in frequency of occurrence of cleareggs.

According to some embodiments of the present invention, analyzing theoutput signals of each optical channel to determine whether the opticalpath between any of the light source/light detector pairs has beenaltered includes detecting an increase in average light level of liveeggs in an optical channel relative to historical values for thatchannel.

According to some embodiments of the present invention, analyzing theoutput signals of each optical channel to determine whether the opticalpath between any of the light source/light detector pairs has beenaltered comprises detecting an increase in average light level of liveeggs in an optical channel relative to historical values for otheroptical channels.

According to some embodiments of the present invention, analyzing theoutput signals of each optical channel to determine whether the opticalpath between any of the light source/light detector pairs has beenaltered comprises detecting a reduction in light levels received at alight detector in an optical channel relative to historical light levelsfor the optical channel.

According to some embodiments of the present invention, an apparatus forcandling eggs includes a light source configured to illuminate an eggwith light from one or more selected portions of the spectrum; a lightdetector that receives light passing through an egg and that generatesan output signal that corresponds to light received at the lightdetector for the egg; and a processor in communication with the lightdetector that analyzes the output signal to determine whether an opticalpath between the light source and light detector has been altered.

According to some embodiments of the present invention, the candlingapparatus includes a wiper that is operatively controlled by theprocessor and that is configured to wipe a surface of the light sourceand/or light detector and remove debris/material therefrom.

According to some embodiments of the present invention, the candlingapparatus includes a cleaning fluid application system that isoperatively controlled by the processor and that is configured to spraya surface of the light source and/or light detector with a fluid (e.g.,a cleaning fluid, water, air, etc.).

According to some embodiments of the present invention, the candlingapparatus includes a sheet of transparent material positioned adjacentto the light source that prevents debris from altering the optical pathbetween the light source and light detector. The transparent materialmoves relative to the light source and is configured to carry awaydebris in contact therewith.

According to some embodiments of the present invention, the candlingapparatus includes a sheet of transparent material positioned adjacentto the light detector that prevents debris from altering the opticalpath between the light source and light detector. The transparentmaterial moves relative to the light detector and is configured to carryaway debris in contact therewith.

According to some embodiments of the present invention, the processor isconfigured to detect whether an average opacity value of clear eggscandled via an optical channel has dropped below an average opacityvalue of clear eggs candled via the other optical channels.

According to some embodiments of the present invention, the processor isconfigured to detect a drop in frequency of occurrence of clear eggs.

According to some embodiments of the present invention, the processor isconfigured to detect an increase in average light level of live eggs.

According to some embodiments of the present invention, the processor isconfigured to detect a reduction in light levels relative to historicallight levels.

According to some embodiments of the present invention, an apparatus forcandling eggs includes a plurality of pairs of light sources and lightdetectors in spaced apart relationship such that eggs may passtherebetween, wherein each light source is configured to illuminate anegg with light from one or more selected portions of the spectrum,wherein each light detector is configured to receive light passingthrough an egg and to generate an output signal that corresponds tolight received at the light detector for the egg, and wherein each lightsource/light detector pair defines a respective optical channel; and aprocessor in communication with each optical channel that analyzes theoutput signals of each optical channel to determine whether an opticalpath between a light source and respective light detector has beenaltered.

According to some embodiments of the present invention, the processor isconfigured to detect whether an average opacity value of clear eggscandled via an optical channel has dropped below an average opacityvalue of clear eggs candled via the other optical channels.

According to some embodiments of the present invention, the processor isconfigured to detect a drop in frequency of occurrence of clear eggs.

According to some embodiments of the present invention, the processor isconfigured to detect an increase in average light level of live eggs inan optical channel relative to historical values for that channel.

According to some embodiments of the present invention, the processor isconfigured to detect an increase in average light level of live eggs inan optical channel relative to historical values for other opticalchannels.

According to some embodiments of the present invention, the processor isconfigured to detect a reduction in light levels received at a lightdetector in an optical channel relative to historical light levels forthe optical channel.

According to some embodiments of the present invention, the candlingapparatus includes a wiper that is operatively controlled by theprocessor and that is configured to wipe a surface of the light sourceand/or light detector and remove debris/material therefrom.

According to some embodiments of the present invention, the candlingapparatus includes a cleaning fluid application system that isoperatively controlled by the processor and that is configured to spraya surface of the light source and/or light detector with a fluid (e.g.,a cleaning fluid, water, air, etc.).

According to some embodiments of the present invention, the candlingapparatus includes a sheet of transparent material positioned adjacentto the light source that prevents debris from altering the optical pathbetween the light source and light detector. The transparent materialmoves relative to the light source and is configured to carry awaydebris in contact therewith.

According to some embodiments of the present invention, the candlingapparatus includes a sheet of transparent material positioned adjacentto the light detector that prevents debris from altering the opticalpath between the light source and light detector. The transparentmaterial moves relative to the light detector and is configured to carryaway debris in contact therewith.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an egg processing system having an eggcandling apparatus, according to some embodiments of the presentinvention.

FIG. 2 is a block diagram of a light source and light detector pair fromthe candling apparatus of FIG. 1.

FIG. 3 is an end view of an exemplary candling apparatus illustrating anegg carrier positioned between a light source mounting block containinga plurality of light sources and a light detector mounting blockcontaining a plurality of light detectors, according to some embodimentsof the present invention.

FIG. 4A is a perspective view of the candling apparatus of FIG. 3 thatillustrates a plurality of light sources in the light source mountingblock.

FIG. 4B is a perspective view of the candling apparatus of FIG. 3 thatillustrates a plurality of light detectors in the light detectormounting block.

FIG. 5 is a partial enlarged cross-sectional view of the light sourceand light detector mounting blocks of FIG. 3.

FIGS. 6-8 are flow charts of operations for maintaining effectiveoperation of candling devices, according to some embodiments of thepresent is invention.

FIG. 9 is a perspective view of the candling apparatus of FIG. 3 havinga wiper that is configured to wipe a surface of the light detectors,according to some embodiments of the present invention.

FIG. 10 is a perspective view of the candling apparatus of FIG. 3 havinga cleaning fluid application system that is configured to spray asurface of the light detectors with a cleaning fluid, according to someembodiments of the present invention.

FIG. 11 is a perspective view of the candling apparatus of FIG. 3 havinga moving sheet of transparent material positioned adjacent to the lightdetectors that catches and removes debris away from the light detectors,according to some embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now is described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art.

Like numbers refer to like elements throughout. In the figures, thethickness of certain lines, layers, components, elements or features maybe exaggerated for clarity. Broken lines illustrate optional features oroperations unless specified otherwise. All publications, patentapplications, patents, and other references mentioned herein areincorporated herein by reference in their entireties.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof. As used herein, the term “and/or”includes any and all combinations of one or more of the associatedlisted items. As used herein, phrases such as “between X and Y” and“between about X and Y” should be interpreted to include X and Y. Asused herein, phrases such as “between about X and Y” mean “between aboutX and about Y.” As used herein, phrases such as “from about X to Y” mean“from about X to about Y.”

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the specification andrelevant art and should not be interpreted in an idealized or overlyformal sense unless expressly so defined herein. Well-known functions orconstructions may not be described in detail for brevity and/or clarity.

It will be understood that when an element is referred to as being “on”,“attached” to, “connected” to, “coupled” with, “contacting”, etc.,another element, it can be directly on, attached to, connected to,coupled with or contacting the other element or intervening elements mayalso be present. In contrast, when an element is referred to as being,for example, “directly on”, “directly attached” to, “directly connected”to, “directly coupled” with or “directly contacting” another element,there are no intervening elements present. It will also be appreciatedby those of skill in the art that references to a structure or featurethat is disposed “adjacent” another feature may have portions thatoverlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”,“upper” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is inverted, elements described as “under” or “beneath” otherelements or features would then be oriented “over” the other elements orfeatures. Thus, the exemplary term “under” can encompass both anorientation of “over” and “under”. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly. Similarly, the terms“upwardly”, “downwardly”, “vertical”, “horizontal” and the like are usedherein for the purpose of explanation only unless specifically indicatedotherwise.

It will be understood that, although the terms “first”, “second”, etc.may be used herein to describe various elements, components, regions,layers and/or sections, these elements, components, regions, layersand/or sections should not be limited by these terms. These terms areonly used to distinguish one element, component, region, layer orsection from another element, component, region, layer or section. Thus,a “first” element, component, region, layer or section discussed belowcould also be termed a “second” element, component, region, layer orsection without departing from the teachings of the present invention.The sequence of operations (or steps) is not limited to the orderpresented in the claims or figures unless specifically indicatedotherwise.

FIG. 1 is a block diagram of an egg processing system 5 having an eggcandling apparatus 30 that is configured to identify live eggs,according to embodiments of the present invention. A carrier (e.g., anegg flat) 10 of eggs 12 is conveyed via a conveyor 22 to the candlingapparatus 30 that is configured to designate each egg 12 within the flat10 as being either live or non-live. Any type of conveying systemsuitable for conveying flats of eggs may be utilized in accordance withembodiments of the present invention. Egg conveying systems are wellknown to those of skill in the art and need not be described furtherherein.

Although eggs conventionally are carried in egg flats, any means ofpresenting a plurality of eggs over time to a candling station 30, aswell as to other egg processing equipment, may be used. Egg flats ofvirtually any type may be used in accordance with embodiments of thepresent invention. Flats may contain any number of rows, such as sevenrows of eggs, with rows of six and seven being most common. Moreover,eggs in is adjacent rows may be parallel to one another, as in a“rectangular” flat, or may be in a staggered relationship, as in an“offset” flat. Examples of suitable commercial flats include, but arenot limited to, the “CHICKMASTER 54” flat, the “JAMESWAY 42” flat andthe “JAMESWAY 84” flat (in each case, the number indicates the number ofeggs carried by the flat). Egg flats are well known to those of skill inthe art and need not be described further herein.

The candling apparatus 30 includes a plurality of light sources thatilluminate eggs within a carrier with light and a plurality ofcorresponding light detectors that receive light passing through theeggs from the light sources and that generate an output signal thatcorresponds to received light, as will be described below. An exemplarylight candling apparatus that may be utilized in accordance with someembodiments of the present invention is described in, for example, U.S.Pat. No. 5,745,228 to Hebrank et al. A suitable commercial lightcandling system that may be utilized in accordance with some embodimentsof the present invention includes, for example, the S Beam lightcandling system of the Egg Remover® candling system available fromEmbrex, Inc. of Research Triangle Park, N.C.

The illustrated candling apparatus 30 is operatively connected to aprocessor 40 which controls operations of the candling apparatus 30,analyzes the output signal from each light detector and storesinformation received from the candling apparatus 30 about each egg 12.An operator interface (e.g., a display) 42 may be provided to allow anoperator to interact with the processor 40. The processor 40 may controlvarious other downstream egg processing operations, as well, including,for example, an egg removal station 50 and backfill station 60.

In the illustrated apparatus, eggs 12 designated as non-live are removedfrom the flat 10 downstream from the candling apparatus 30 at eggremoval station 50. The processor 40 generates a selective removalsignal for eggs determined to be non-live by the candling apparatus 30.The non-live eggs are removed from the flat 10 and discarded or used forsome other purpose.

FIG. 2 illustrates an exemplary light source 32 and light detector 34pair from the candling apparatus 30 of FIG. 1. The candling apparatus 30contains a plurality of light source/light detector pairs to correspondwith a row of eggs in a carrier, such as an egg flat. Each lightsource/light detector pair defines a respective optical channel. Eachlight detector 34 is associated with a detector amplifier and filtercircuit 35, which is in turn associated with an analog input board 36.Each light source 32 (e.g., an infrared light source, etc.) isassociated with a light source driver circuit 33, which is in turnassociated with a digital output board 37. The light source 32 and lightdetector 34 in each pair are positioned on opposite sides of an egg, aswould be understood by those skilled in the art. In FIG. 2, the lightdetector 34 is above and the light source 32 is below the egg, but thesepositions are not critical and could be reversed, or the light sourceand light detector may be placed in different orientations, so long aslight from the light source illuminates the egg to the light detector.Embodiments of the present invention are not limited to the illustratedorientation and configuration of the light source 32 and light detector34.

The input and output boards 36, 37 may physically be one or moreseparate boards and are associated with a processor 38 (e.g., a personalcomputer or other computing device), with operation of the systemmonitored on a user interface 39 associated with the processor. Inoperation, light is generated in short bursts from each light source 32(e.g., 50 to 300 microseconds) and the corresponding light detector 34monitors while its corresponding light source 32 is operational. Toreduce the effect of ambient light, the output of a light detector 34when no light is on is subtracted from the reading when the light is on.A flat of eggs is continuously “scanned” as it moves through thecandling apparatus 30 with each light detector/light source pair activewhile at least adjacent, and preferably all other, light detector/lightsource pairs are quiescent.

FIG. 3 is an end view of a candling apparatus 30, according to someembodiments of the present invention. The candling apparatus 30 includesa light source mounting block 71 containing a plurality of light sources32 disposed therewithin in adjacent, spaced-apart relationship (FIG. 5),and a light detector mounting block 70 containing a plurality of lightdetectors 34 disposed therewithin in adjacent, spaced-apart relationship(FIG. 5). The illustrated candling apparatus 30 also includes a conveyor22 that transports egg carriers 10 containing eggs 12 between the lightsource mounting block 71 and the light detector mounting block 70.

FIG. 5 is a partial enlarged cross-sectional view of the light sourceand light detector mounting blocks 71, 70 of FIG. 3. The illustratedlight source mounting block 71 includes an opaque back plate 72 withlight sources 32 (e.g., Photonics Detectors, Inc. infrared lightsources, Part number PDI-E805, etc.) disposed therewithin. These lightsources 32 include an integral lens, but a non-integral lens system mayalso be provided for each light source. The illustrated light sourcemounting block 71 also includes an opaque polymer block 73 attached tothe back plate 72. The polymer block 73 has apertures bored therethroughin corresponding relation to each light source 32. The light sourcemounting block 71 also includes sapphire disks 80 disposed within therespective apertures formed in the block 73 so as to be generally flushwith the upper surface 73 a thereof. Each sapphire disk 80 protects arespective light source 32 by preventing debris (e.g., liquids, etc.)from passing through an aperture and reaching a light source 32. Inaddition, each sapphire disk 80 provides a generally flat surface thatcan be cleaned easily and that does not accumulate or pool water andother materials/liquids. Sapphire is sufficiently hard that routinewiping will not scratch the surface and cause light to scatter on toadjacent eggs. However, the disks 80 may be formed from other materials.Embodiments of the present invention are not limited to sapphire disks.The structure of the mounting block 71 thus provides an optical aperturepositioned between an egg and a respective light source 32 with asurface (e.g., sapphire disk 80) that prevents debris from damaging thelight source 32.

The light detector mounting block 70 has a similar construction. Theillustrated light detector mounting block 70 includes an opaque backplate 75 with light detectors 34 (e.g., Texas Instruments infrareddetectors, Part number TSL261, etc.) disposed therewithin. Integrallenses or non-integral lens systems could optionally be provided withthe light detectors 34. The illustrated light detector mounting block 70also includes an opaque polymer block 76 attached to the back plate 75.The polymer block 76 has apertures bored therethrough in correspondingrelation to each light detector. The light detector mounting block 76also includes sapphire disks 80 disposed within the respective aperturesformed in the block 76 so as to be generally flush with the lowersurface 76 a thereof. Each sapphire disk 80 protects a respective lightdetector 34 by preventing debris (e.g., liquids, etc.) from passingthrough an aperture and reaching a light detector 34. In addition, eachsapphire disk 80 provides a generally flat surface that can be cleanedeasily and that does not accumulate or pool water and othermaterials/liquids. As described above, the disks 80 may be formed fromother materials. Embodiments of the present invention are not limited tosapphire disks. The structure of the mounting block 76 thus provides anoptical aperture positioned between an egg and a respective lightdetector 34 with a surface (e.g., sapphire disk 80) that prevents debrisfrom damaging the light detector 34.

Blocks 73, 76 may be formed from various materials and are not limitedto polymer materials.

FIG. 4A is a perspective view of the candling apparatus 30 of FIG. 3illustrating block surface 73 a having a plurality of sapphire disks 80substantially flush therewith. FIG. 4B is a perspective view of thecandling apparatus 30 of FIG. 3 illustrating block surface 76 a having aplurality of sapphire disks 80 substantially flush therewith.

Embodiments of the present invention are not limited to the illustratedcandling apparatus 30. Embodiments of the present invention may beimplemented with any candling apparatus, without limitation.

Referring now to FIGS. 6-8, methods of candling eggs that facilitatemaintaining effective candling operation, according to embodiments ofthe present invention, are illustrated. Initially, a determination ismade whether the optical path (i.e., the optical path from a lightsource 32 to a light detector 34) of a candling apparatus has beenaltered (Block 100). In response to determining that the optical pathhas been altered, altering materials (e.g., egg debris, water, etc.) isremoved from the optical path or neighboring region (Block 200) and/orthe light source/light detector pair is inspected for malfunctions(Block 300). Determining whether the optical path of a candling devicehas been altered can be performed in various ways. For example, an eggis illuminated with light from a light source 32 during candlingoperations and light passing through the egg is received at acorresponding light detector 34. The light detector 34 generates asoutput signal that corresponds to the light received at the lightdetector 34. The output signal is analyzed in one or more various waysto determine if the optical path has been altered by, for example,debris covering the optical path between the light source 32 and/orlight detector 34.

Output signal analysis may include, but is not limited to, detecting adrop in the mean light level of clear eggs (e.g., detecting that theaverage opacity of clear eggs on one channel drops below the average ormedian of the average of other channels of the candling apparatus)(Block 110); detecting a drop in the frequency of occurrence of cleareggs (e.g., the percent of clear eggs on one channel drops below that ofother channels of a candling device) (Block 120); detecting an increasein the average light level of live eggs in one channel relative tohistorical values for that channel and/or values for other channels of acandling device (Block 130); and detecting reduced light levelstransmitted between eggs from the light sources to the light detectorsof a candling apparatus (Block 140). In addition, other ways ofdetermining whether the optical path of a candling apparatus lightsource/light detector pair has been altered, according to someembodiments of the present invention, include time-based, cycle-based orrandom assumptions that light sources and/or light detectors should becleaned, and manual observations by an operator of a candling apparatus.

High light values for live eggs, which falsely indicate that a live eggis a clear egg, can happen when water and/or egg material forms on alens on a light detector or light source, and/or when fog (e.g.,condensation, etc.) causes a light detector to gather stray light fromlight sources or a light source to scatter light to the side. Generally,when a live egg on one optical channel is consistently seen as a clearegg, the light detectors and light sources should be cleaned and/orchecked for fogging.

Removing altering materials from the optical path or neighboring regionof a candling apparatus can be performed in various ways in accordancewith some embodiments of the present invention. For example, thesurface(s) of light sources and/or light detectors (and/or the surfacesof protective materials overlying the light sources/light detectors,such as the sapphire disks 80 described above) can be wiped (e.g.,automatically or manually) (Block 210); the surface(s) of light sourcesand/or light detectors (and/or the surfaces of protective materialsoverlying the light sources/light detectors, such as the sapphire disks80 described above) can be sprayed with a fluid (e.g., a cleaning fluid,water, air, etc.) (Block 220); and/or a moving transparent film thatblocks debris from reaching the surface(s) of light sources and/or lightdetectors and carries the debris away may be utilized (Block 230). Forexample, in the illustrated candling apparatus embodiment of FIG. 5, thesurfaces 73 a, 76 a of respective blocks 73, 76 and the sapphire disks80 may be wiped and/or sprayed with a fluid to remove debris therefrom.

It is understood that the phrase “cleaning a light source and/or lightdetector”, as used herein, means cleaning the surfaces of protectivematerials overlying the light sources/light detectors, such as thesapphire disks 80 described above, as well as the light sources/lightdetectors, themselves. The phrase “cleaning a light source and/or lightdetector”, as used herein, also means cleaning surfaces adjacent to thelight sources/light detectors.

FIG. 9 illustrates the candling apparatus 30 of FIG. 3 with a wiper 80that is configured to wipe the surface 73 a of block 73 and the sapphiredisks 80, according to some embodiments of the present invention. Asimilar wiper may be used to wipe the surface 76 a of block 76 housingthe light detectors 34. Wiper 80 may have various configurations and maybe similar in configuration and operation as a wipe blade for a vehiclewindshield.

FIG. 10 illustrates the candling apparatus 30 of FIG. 3 with a cleaningfluid application system 82 that is configured to spray the surface 73 aof the block 73 housing the light sources 32 and the sapphire disks 80with a cleaning fluid, according to some embodiments of the presentinvention. In the illustrated embodiment, a series of nozzles 84 areconfigured to spray fluid (e.g., a cleaning fluid, water, air, etc.)onto the surface 73 a and sapphire disks 80. A similar spray system maybe used to clean the surface 76 a of the block 76 housing the lightdetectors 34.

FIG. 11 illustrates the candling apparatus 30 of FIG. 3 with a sheet oftransparent material 90 positioned adjacent to the block 73 housing thelight detectors 32. The sheet of material 90 is configured to catchdebris and periodically move in the direction indicated by arrow 92 toremove the debris away from the light sources 32. A similar system maybe used to catch and remove debris from the surface 76 a of the block 76housing the light detectors 34.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. The invention is defined by the following claims, withequivalents of the claims to be included therein.

1. A method of candling eggs with a candling apparatus, wherein thecandling apparatus comprises a plurality of pairs of light sources andlight detectors in spaced apart relationship such that a carrier of eggsmay pass therebetween, wherein each light source/light detector pair isoperatively associated with a processor, wherein each light source/lightdetector pair defines a respective optical channel, the methodcomprising: a) illuminating eggs in a carrier with light from the lightsources, wherein the eggs are arranged in rows and columns within thecarrier, and wherein each egg in a row is positioned between arespective light source/light detector pair; b) receiving light passingthrough each egg at a corresponding light detector; c) generating anoutput signal that corresponds to light received at a light detector foreach respective egg; and d) analyzing the output signals of each opticalchannel to determine whether an optical path between any of the lightsource/light detector pairs has been altered by debris and/or by amalfunctioning light source or light detector; wherein analyzing theoutput signals of each optical channel to determine whether the opticalpath between any of the light source/light detector pairs has beenaltered comprises detecting whether an average opacity value of cleareggs candled via an optical channel has dropped below an average opacityvalue of clear eggs candled via the other optical channels.
 2. Themethod of claim 1, further comprising analyzing the output signals ofeach optical channel to determine whether the optical path between anyof the light source/light detector pairs has been altered comprisesdetecting an increase in average light level of live eggs in an opticalchannel relative to historical values for that channel.
 3. The method ofclaim 1, further comprising analyzing the output signals of each opticalchannel to determine whether the optical path between any of the lightsource/light detector pairs has been altered comprises detecting anincrease in average light level of live eggs in an optical channelrelative to historical values for other optical channels.
 4. The methodof claim 1, further comprising analyzing the output signals of eachoptical channel to determine whether the optical path between any of thelight source/light detector pairs has been altered comprises detecting areduction in light levels received at a light detector in an opticalchannel relative to historical light levels for the optical channel. 5.The method of claim 1, further comprising inspecting a respective lightsource and/or light detector in response to determining that arespective optical path has been altered.
 6. The method of claim 1,further comprising cleaning a respective light source and/or lightdetector in response to determining that a respective optical path hasbeen altered.
 7. The method of claim 6, wherein cleaning the respectivelight source and/or light detector comprises removing optical pathaltering materials from the respective light source and/or lightdetector.
 8. The method of claim 6, wherein cleaning the respectivelight source and/or light detector comprises wiping a surface of therespective light source and/or light detector.
 9. The method of claim 6,wherein cleaning the respective light source and/or light detectorcomprises spraying a surface of the respective light source and/or lightdetector with a cleaning fluid.
 10. A method of candling eggs with acandling apparatus, wherein the candling apparatus comprises a pluralityof pairs of light sources and light detectors in spaced apartrelationship such that a carrier of eggs may pass therebetween, whereineach light source/light detector pair is operatively associated with aprocessor, wherein each light source/light detector pair defines arespective optical channel, the method comprising: a) illuminating eggsin a carrier with light from the light sources, wherein the eggs arearranged in rows and columns within the carrier, and wherein each egg ina row is positioned between a respective light source/light detectorpair; b) receiving light passing through each egg at a correspondinglight detector; c) generating an output signal that corresponds to lightreceived at a light detector for each respective egg; and d) analyzingthe output signals of each optical channel to determine whether anoptical path between any of the light source/light detector pairs hasbeen altered by debris and/or by a malfunctioning light source or lightdetector; wherein analyzing the output signals of each optical channelto determine whether the optical path between any of the lightsource/light detector pairs has been altered comprises detecting a dropin frequency of occurrence of clear eggs.
 11. An apparatus for candlingeggs, comprising: a light source configured to illuminate an egg withlight from one or more selected portions of a spectrum; a light detectorthat receives light passing through an egg and that generates an outputsignal that corresponds to light received at the light detector for theegg; a processor in communication with the light detector that analyzesthe output signal to determine whether an optical path between the lightsource and light detector has been altered by debris and/or by amalfunctioning light source or light detector; an operator interfacethat allows an operator to interact with the processor; and a wiperoperatively controlled by the processor that is configured to wipe asurface of the light source and/or light detector.
 12. The apparatus ofclaim 11, further comprising a sheet of transparent material positionedadjacent to the light source that prevents debris from altering theoptical path between the light source and light detector.
 13. Theapparatus of claim 11, further comprising a sheet of transparentmaterial positioned adjacent to the light detector that prevents debrisfrom altering the optical path between the light source and lightdetector.
 14. The apparatus of Claim 12, wherein the transparentmaterial moves relative to the light source and is configured to carryaway debris in contact therewith.
 15. The apparatus of Claim 13, whereinthe transparent material moves relative to the light detector and isconfigured to carry away debris in contact therewith.
 16. An apparatusfor candling eggs, comprising: a light source configured to illuminatean egg with light from one or more selected portions of a spectrum; alight detector that receives light passing through an egg and thatgenerates an output signal that corresponds to light received at thelight detector for the egg; a processor in communication with the lightdetector that analyzes the output signal to determine whether an opticalpath between the light source and light detector has been altered bydebris and/or by a malfunctioning light source or light detector; anoperator interface that allows an operator to interact with theprocessor; and a cleaning fluid application system operativelycontrolled by the processor and that is configured to spray a surface ofthe light source and/or light detector with a cleaning fluid.
 17. Theapparatus of claim 16, wherein the processor is configured to detectwhether an average opacity value of clear eggs candled via an opticalchannel has dropped below an average opacity value of clear eggs candledvia other optical channels.
 18. The apparatus of claim 16, wherein theprocessor is configured to detect a drop in frequency of occurrence ofclear eggs.
 19. The apparatus of claim 16, wherein the processor isconfigured to detect an increase in average light level of live eggs.20. The apparatus of claim 16, wherein the processor is configured todetect a reduction in light levels relative to historical light levels.21. An apparatus for candling eggs, comprising: a plurality of pairs oflight sources and light detectors in spaced apart relationship such thateggs may pass therebetween, wherein each light source is configured toilluminate an egg with light from one or more selected portions of aspectrum, wherein each light detector is configured to receive lightpassing through an egg and to generate an output signal that correspondsto light received at the light detector for the egg, and wherein eachlight source/light detector pair defines a respective optical channel; aprocessor in communication with each optical channel that analyzes theoutput signals of each optical channel to determine whether an opticalpath between a light source and a respective light detector has beenaltered by debris and/or by a malfunctioning light source or lightdetector; an operator interface that allows an operator to interact withthe processor, and wherein the processor is configured to detect whetheran average opacity value of clear eggs candled via an optical channelhas dropped below an average opacity value of clear eggs candled via theother optical channels.
 22. The apparatus of claim 21, wherein theprocessor is also configured to detect an increase in average lightlevel of live eggs in an optical channel relative to historical valuesfor that channel.
 23. The apparatus of claim 21, wherein the processoris also configured to detect an increase in average light level of liveeggs in an optical channel relative to historical values for otheroptical channels.
 24. The apparatus of claim 21, wherein the processoris also configured to detect a reduction in light levels received at alight detector in an optical channel relative to historical light levelsfor the optical channel.
 25. The apparatus of claim 21, furthercomprising a sheet of transparent material positioned adjacent to eachlight source that prevents debris from altering the optical path betweeneach light source and a respective light detector.
 26. The apparatus ofclaim 21, further comprising a sheet of transparent material positionedadjacent to each light detector that prevents debris from altering theoptical path between each light source and a respective light detector.27. The apparatus of claim 25, wherein the transparent material movesrelative to the light sources and is configured to carry away debris incontact therewith.
 28. The apparatus of claim 26, wherein thetransparent material moves relative to the light detectors and isconfigured to carry away debris in contact therewith.
 29. An apparatusfor candling eggs, comprising: a plurality of pairs of light sources andlight detectors in spaced apart relationship such that eggs may passtherebetween, wherein each light source is configured to illuminate anegg with light from one or more selected portions of a spectrum, whereineach light detector is configured to receive light passing through anegg and to generate an output signal that corresponds to light receivedat the light detector for the egg, and wherein each light source/lightdetector pair defines a respective optical channel; a processor incommunication with each optical channel that analyzes the output signalsof each optical channel to determine whether an optical path between alight source and a respective light detector has been altered by debrisand/or by a malfunctioning light source or light detector; an operatorinterface that allows an operator to interact with the processor, andwherein the processor is configured to detect a drop in frequency ofoccurrence of clear eggs.
 30. An apparatus for candling eggs,comprising: a plurality of pairs of light sources and light detectors inspaced apart relationship such that eggs may pass therebetween, whereineach light source is configured to illuminate an egg with light from oneor more selected portions of a spectrum, wherein each light detector isconfigured to receive light passing through an egg and to generate anoutput signal that corresponds to light received at the light detectorfor the egg, and wherein each light source/light detector pair defines arespective optical channel; a processor in communication with eachoptical channel that analyzes the output signals of each optical channelto determine whether an optical path between a light source and arespective light detector has been altered by debris and/or by amalfunctioning light source or light detector; an operator interfacethat allows an operator to interact with the processor, and a wiperoperatively controlled by the processor and that is configured to wipe asurface of a light source and/or light detector.
 31. An apparatus forcandling eggs, comprising: a plurality of pairs of light sources andlight detectors in spaced apart relationship such that eggs may passtherebetween, wherein each light source is configured to illuminate anegg with light from one or more selected portions of a spectrum, whereineach light detector is configured to receive light passing through anegg and to generate an output signal that corresponds to light receivedat the light detector for the egg, and wherein each light source/lightdetector pair defines a respective optical channel; a processor incommunication with each optical channel that analyzes the output signalsof each optical channel to determine whether an optical path between alight source and a respective light detector has been altered by debrisand/or by a malfunctioning light source or light detector; an operatorinterface that allows an operator to interact with the processor, andfurther comprising a cleaning fluid application system operativelycontrolled by the processor and that is configured to spray a surface ofa light source and/or light detector with a cleaning fluid.